No. 1_2017

ON A WORLD-CLASS LEVEL The Shanghai Tobacco Group and a state-of-the-art cigarette factory

e FOR EFFICIENT PROTOS-M5e – the world’s most HiLiTE efficient maker in the 12,000 cpm sector Published for the Tobacco Industry HEAT-NOT-BURN Innovations in the industry’s fastest growing market

THE HUMAN FACTOR

How technology has transformed THE HUMAN ROLE in industrial production. EDITORIAL HiLiTE 1_17 3 - re also looking at the opportunities also looking at the opportunities re a MACHINE OF MAN AND OF MAN in this issue. We in this issue. We the worlds to create for connecting virtual and real the ways that digitiza- and workplaces of the future, human errors. tion can prevent some of the latest innova- In addition, we will present and precision Hauni: the unprecedented tions from maker in the flexibility of the KDF 6MF LEAD multifilter ciga most efficient high-speed sector and the world’s – the PROTOS-M5e. maker for the 12,000 sector rette overview of the And last, but not least, we give you an and explore exciting market for heat-not-burn products (without step another taking are beings human how of flight. the dream digital technology) towards the new edition of HiLiTE. hope you will enjoy reading We Jürgen Heller Dr. Member of the Hauni Executive Board - - o truly benefit from this innovative this innovative o truly benefit from is an undisputed fact that Industry 4.0 is chang is an undisputed fact that Industry 4.0 t sec- tobacco the in even work of world the ing new and more more As technology acquires tor. grow into their new roles. What this means in practical What this means in practical into their new roles. grow in our new Smart becoming apparent terms is already Brand Change Management and the VMI+ full service about parts supply solution, which you can read spare capabilities, we face inevitable questions about the about the capabilities, we face inevitable questions beings. In this issue of HiLiTE of human role future and show that we will attempt to find some answers the heart of tomorrow’s at humans still have a future be dif will the tasks However, processes. production between solutions – lies in optimizing the interfaces man and machine. Only when we achieve this goal will we be able t their liberated from symbiosis. Only when people are accustomed tasks will they have the opportunity to ferent and the humans involved will require new skills. new skills. will require and the humans involved ferent – and therefore The key factor in determining success of industrial the main challenge facing manufacturers I

TE IS NOW

i HiLiTE L i

IN AN APP NOW IN AN devices for most mobile Available app in any browser and as a web READ YOUR HiLiTE YOUR READ Along with access to Along with access to the all contents from printed magazine, the app includes many additional features such as animations, graphics and films. H AVAILABLE AS AN APP of It is available free and iTunes charge from the Google Play Store. HiLiTE Marco Castro, HauniServicesChina 1_17 HiLiTE 08 Marco Castro,GeneralManagerServicesofHauniChina. 06 COMPETENCE Unit, E-Kitandanewcontrol system. In-house exhibitionatDecouflé,TobaccoReclaiming 18 A newManagingDirectorinTurkey. The BorgwaldtGroupcelebratesits150thanniversary. 16 with abigimpact. Hauni’s newSmartBrandChange–asmallchange 12 The humanroleinindustrialproduction.

DIRECTORS WANTED WHERE NEWIDEASNEVERRUNOUT FACTS &FIGURES HAUNI WORLDWIDE TAKING THESTRAINOUTOFWORK

06 + VISIONS CONTENTS reduces stocksofspareparts byupto40percent. The fullservicesparepartssupply solutionVMi+ Insights intothefastestgrowingmarketinindustry. 32 30 VR applicationshelpustounderstandprocessesbetter. 29 new dimensions. Industries areembracingvirtualrealityandopeningup 26 state-of-the-art cigaretteproductionfacility. A visittoTheShanghaiTobaccoGroupandits 20 CHALLENGES

  PERSPECTIVE FULL SERVICEFORSPARE PARTS HEAT-NOT-BURN VIRTUAL REALITYATHAUNI SEEING THINGSFROMANEW LEVEL OPTIMIZATION ONAWORLD-CLASS + SOLUTIONS

34 improved qualitycontrol. The newICPS-CSsensorfor specialfiltersoffers 45 processes fornon-wrappedhollowfilters. Hauni presentsthefirstmachinewithtwoalternative 44 stands formaximumprecisionandflexibility. The high-speedmultifiltermakerKDF6MFLEAD 40 into alternativetobaccomaterials. An overviewofHaunisolutionsforprocessingrecon 38 maker forthe12,000cpmsector. Hauni presentstheworld’smostefficientcigarette

CROSS SECTIONCHECK FILTER DIVERSITY LEADer OFTHEPACK REUSED TOBACCO e FOREFFICIENT

KDF 6MFLEAD:ablueprintfrom nature Trend: virtualreality 55 03 Fly likeabird:wingsuitpilots. 54 results oftheirchallengingfinalproject. Hauni mechatronicsapprenticespresentthe 52 harnessed andusedasanenergysource. The naturalmovementofbacteriacouldbe 50 simple measurescanboostreliability. Human errorisasubstantialprocessrisk.Afew 46 EXPERIENCE

 PREVIEW EDITORIAL EXTREME SPORT NETWORKING FROMDAYONE BACTERICAL WINDFARM FACTOR REMAINING RISK–THEHUMAN

hn-1090_Falzposter_Decoufle_rz_120417.indd 1-3

LOGISTICS

FILTER

PLAIN

FILTER

RECON

RESY-DCL

RTS Nano-C (with FN-C)

RESERVOIRS

MASSFLOW

FILTERED

MAKERS

Reservoir for double length products Rod transfer system

Double length base rod with fi lter and straight seam

HEAD

+ RESPONSIBILITY

SHAPED

UNIFLOW 2 MAGOMAT-C

LU UF-I

HANDLING 26 40 TRAY

Tray fi ller for double length Tray fi ller

Tray fi ller Tray discharger

FILTER TIP

OVERWRAPPING

SP4 FLOW

OVERWRAPPING

NATURAL LEAF

SPIRAL

Spiral wrapper Spiral wrapper line

SAF

MASSFLOW

FEED Filter rod feeding

BASIC WRAPPING

(RECON PAPER)

WITHOUT FILTER

Options: cutting, tipping paper, tip turner,

MAX-C

MAX-DCT

cigar band, laser perforations

VARIOUS DESIGNS FOR:

PROCESSING

FINAL

SERVICE: full product life-cycle support

Application for natural leaf overwrap Application for spiral overwrap

SPIRAL OVERWRAPPED WRAPPING

(WITH RECON PAPER) 34 Miracle ofefficiency:thePROTOS-M5e 30

APPLICATION

FILTER TIP

RECON

Nano-C (with ET)

MAKERS

Double length base rod with straight seam

OVERWRAPPED NATURAL LEAF Growing market: Heat-not-burn

Variomat-N

HEAD SHAPING

Double length rod

Nano-C

NO TIPPING

OVERWRAPPING

NATURAL LEAF

TIPPING PAPER

SP4 FLOW OVERWRAPPING

SPIRAL

TIPPING

Spiral wrapper Spiral wrapper line

CIGAR BAND

optional

Options: cutting, tipping paper, tip turner,

MAX-C

MAX-DCT

cigar band, laser perforations

PERFORATION

PROCESSING

Non-Hauni products

FINAL

Application for natural leaf overwrap Application for spiral overwrap

APPLICATION

FILTER TIP

Hauni Maschinenbau GmbH | May 2017 and cigarillos. the production ofcigars as Decouflémachines for packing filtertubesaswell available for makingand overview ofproducts The posterprovides an 18/19

www.decoufl e.com

Cigarillos

Cigars &

POSTER

smart. diverse. compact.

12.04.17 19:50 COMPETENCE + VISIONS HiLiTE 1_17 7

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his family, he spent the next few years getting to know his family, people, customs and traditions.and its country the and he loves the fact Shanghai is “his” metropolis it is the com that the city never sleeps. However, the differ bination of old and new that makes oppositestwo these “Here Shanghai. in ence says other,” do not clash, but complement each way is learning In business too, the best from Castro. that hit the mark. innovations the old to create team in China that has built up a 55-strong Castro works with a highly solution and customer-driven Off- Consulting sector. in the Services and approach fit into the business here. don’t the-shelf products and have aHis team members trust one another appre distinct “can-do” spirit, which he immensely the most ciates. For him, passion and conviction are for doing a good job. important prerequisites he sees his main task in acqui- As a manager, implementa sition management and project understands contracts with cus tion. Castro tomers as the framework within which his team develops innovations. “I always ask myself what the customer expects of us to make him feel reas When that he has bought the right product.” sured talks about his business, you quickly notice Castro than just a job to him. He loves that this is more time what he does. He spends what little spare with he has with friends, tries out new restaurants them and – even after twelve years – continues about this and more every day to discover more great city that has so much to offer. great - - - - -

oasts oasts for browsers and mobile devices. HiLiTE App Discover more photos with the new Discover more photos with the new e city he lives in and in which he promotes e city he lives in and in which he promotes h ide the Hauni Services business in China is - al for innovations. Shanghai, with a popu VR nomic centre of the country. Furthermore, it b Furthermore, of the country. nomic centre and is an the biggest container port in the world Life is ex important cultural and education centre. making it just the right international tremely here, Born Castro. in Lima in 1964, he place for Marco several years in be up in his hometown with grew At the tween spent in Hamburg and Barcelona. His age of 22, he attended Hamburg University. In 1996, first job was in marketing and PR in 1990. he sold machines for he moved to Colombia where the Peruvian A few years later, the textile industry. he met his national moved back to Germany where wife, spent a year looking after his newly born son, and joined Hauni in 2001. was sent to China as a customer In 2005, Castro had to fight for that, because consultant. “I really naturally they wanted me for the business in South But he did succeed, reports. America,” Castro and today is still pleased with the way things have turned out. is somewhat unusual: “I want Why China? His reply speak the language, I don’t ed to go to a place where know the market and am unfamiliar with the don’t sees challenges The 53-year-old mentality.” country’s with Together rather than a threat. as a motivating force lation of around 23 million, is one of the world’s is one of the world’s 23 million, lation of around eco and the most important largest metropolises T Old and new do not clash here, Old and new do not clash here, but complement each other.” “ General Manager Services of Hauni China, is pleased when a problem when a problem Hauni China, is pleased Manager Services of General

crops up, because what he enjoys most is developing new ideas and finding solutions. ideas and finding new is developing most up, because what he enjoys crops MARCO CASTRO, MARCO CASTRO, NEVER RUN OUT RUN NEVER WHERE NEW IDEAS IDEAS NEW WHERE

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HiLiTE 1_17 HiLiTE COMPETENCE VISIONS +

Ability to continuously

exchange information with + machines and networks VISIONS

COMPETENCE 67%

More active participation Willingness to in problem-solving and engage in life-long optimization processes 71% 85% learning

Reinforcement of interdisciplinary 70% thinking and action

lthough people may be more familiar with According to a recent study, these four principal “Spinning Jenny” as the heroine of a hit competences are required for the implementation of Country & Western song, she also played Industry 4.0. You can read the full study here: a vital part in the industrial revolution and www.ingenics.de/download-studie-i40-16 in redefining the role of humans in manu- facturingA processes. She should not be forgotten or un- production scheduling and analyzed workflows in terms derestimated. And, of course, “she” was not a lady but a of methods and the locations and times that work was machine. The steam engine may have stolen the headlines performed. They divided up tasks into precise steps for as the greatest milestone of the industrial revolution, but greater efficiency and specified detailed targets. Commu- “Jenny” came first. She initially demonstrated the prin- nication was restricted to the absolute minimum and was ciples that were to be the foundation of factory produc- a one-way street from the top levels to the bottom. tion in England in the second half of the 18th century. The “Spinning Jenny” was the first mechanical spinning frame Chips replace brain cells and “ground zero” for the transition from manual to more The first machine age, in which human muscle power was efficient, machine-based processes. Before its invention, a replaced by machines and new forms of motive power, large number of spinners were required to prepare an ad- was succeeded by a second. If anything, this changed equate supply of yarn for each weaver. Now, only one was the human role in industrial production even more radi- needed. The increase in productivity was revolutionary. cally and its impact is still felt today. It began with the DIRECTORS third industrial revolution. The 1970s saw the widespread Machines replace muscles adoption of information technology and electronics in fac- Greater productivity and new responsibilities for manu- tories and automated production processes. Machines WANTED facturing workers also characterized the second industri- took over complete stages of production on a large scale al revolution, which was again triggered by technological including tasks which had previously been considered progress. In 1870, the first production lines were intro- impossible without uniquely human attributes, such as Machines are replacing muscle power and performing tasks that duced in abattoirs in Cincinnati. At the beginning of the a brain or the ability to see. It quickly became clear that were once the preserve of the human brain. They have been do- 20th century, electricity for the first time facilitated mass computers and other digital technologies would have ing so for centuries. Each technological advance has redefined production based on the division of labor and the adop- similar consequences for brain power – and its ability to tion of new forms of industrial organization. These were understand and shape its surroundings – as the steam

THE ROLE OF HUMAN BEINGS in industrial production processes. based on “scientific management”, a controversial phi- engine and its successors had for muscle power. HiLiTE 1_17 HiLiTE losophy of process control, which changed the role of workers dramatically. Here, management took charge of HiLiTE 1_17

9 8 COMPETENCE VISIONS +

+ VISIONS

ince the beginning of the fourth industrial revo- is that nobody currently knows. After the first machine age, COMPETENCE lution, this trend has gathered enormous mo- the human factor was still crucial to the production process. ... mentum. Using a technology concept which However, it is clear that the situation is changing. Machines In the first machine age, production manages systems based on big data and intel- have already mastered human skills in many areas and fur- ligent networks of people, machines and objects ther activities seem likely to follow. machines replaced muscle power – Soperating in real time, we are on the cusp of creating the in the second, they are assuming re- “smart factory”: a self-organizing plant which manufactures New responsibilities sponsibility for the work of the brain. bespoke customer solutions on any scale down to a batch Experts agree that people are not about to disappear com- size of 1 at costs similar to those of mass production. Mo- pletely from production halls any time soon. However, they tors have long performed the work of muscles, now sen- also concur that there will be significant changes in workers’ sors are augmenting the inspection capabilities of the hu- responsibilities and the skills they require. A recent study man eye. Tasks that used to require years of training and conducted by Ingenics AG and Fraunhofer IAO among ex- fine motor skills are now being performed by machines with ecutives of SMEs confirmed their conclusion. They identified superhuman precision. And where factual knowledge was life-long learning as the single most important competence once indispensable, data sets now contain all the key in- required for the implementation of Industry 4.0. This was formation. Industrial robots combine the muscle and brain followed by more active participation in problem-solving and power of technology. optimization processes, reinforcing interdisciplinary thinking Capable of working around the clock, they are formidable and action, and the ability to exchange data between ma- competitors for human beings in the production process. chines and networked systems at all times. Where will this journey end? With constant advances being Professor Dieter Spath, Director of Fraunhofer IAO, is “ab- made in the area of artificial intelligence, the simple answer solutely certain that people will continue to be involved at

the heart of the process – even in a completely virtualized expertise needed for working in networked teams. But In- factory packed with information technology.” He believes dustry 4.0 also opens up new opportunities for less qualified that qualified employees will be need to plug sensory gaps people through the use of assistant-based systems. “which will always exist. Years of experience give them the The types of qualifications that companies are seeking capabilities they need to evaluate and solve problems and clearly show that the humans have a long-term future – and deal with unexpected situations. And, as workers, they also how this will be defined in the new world of the sec- contribute their creativity and flexibility to the processes.” ond machine age. Largely replaced as a “source of motive In summary: the current industrial revolution will generate power” and no longer the only “intelligence” in the factory, higher quality jobs. humans remain in demand as the interfaces, communicators Both now and in the future, the ability of human beings to and directors of increasingly networked and complex tech- control and manage growing complexity in new forms of nological structures. However, if people are going to master economic activity will be the determining factor in success – more complex tasks, they must also be freed from other re- for every sector. Another study, conducted by the industry sponsibilities: from overly simplistic tasks which waste the association BITKOM, also concluded that new technologies abilities they could be applying in other areas. This trend and will not banish human beings from factory halls. “But we be- the associated changes in production structures are now no ... lieve their roles will be transformed. Working with new digi- longer a matter of opinion or technological credibility. They tal technologies requires practice and, generally, companies are the foundation of future competitiveness. Or as a Chi- Humans remain in demand as the need new workers with sound industrial IT skills as well” says nese proverb reminds us, “When the wind of change blows, inter­faces, communicators and direc- Frank Riemensperger, Member of the Board of BITKOM. Ac- some people build walls, others build windmills.” = tors of increasingly networked and cording to the study, businesses are primarily looking for HiLiTE 1_17 HiLiTE highly qualified professionals who offer the interdisciplinary complex technological structures. HiLiTE 1_17

11 10 COMPETENCE + VISIONS HiLiTE 1_17 13

in for either complete or partial conversion kits. either complete or partial conversion for Hauni supplies parts for format changes “smart boxes” as pre-assembled “conversion units” “conversion as pre-assembled “smart boxes”

­

free conversion free - PLANNING TOOL based brand comparison comparison brand based - STEP SYSTEM 2: STORAGE instructions conversion Intuitive error for and exchange parts identification STEP 1: Software not just a question of training. “In the future, factories will future, not just a question of training. “In the workplaces which adapt to em intelligent include ever more them in their work,” ployees’ level of knowledge and support Management the of Chairman Köckler, Jochen explains Developments like these are of Deutsche Messe AG. Board the time and space they to give workers essential in order need to focus and use their skills efficiently. Smart Brand Change Witlake, Consultant at Hauni, works closely Sören Product He regular­ sector every day. the tobacco with customers from some of the greatest offers area this ly notices that precisely ­ ­ fastest The world’s The world’s format change

is one example of a small change that makes a big difference. a small change that makes of is one example commissioning on site on commissioning VISU Smart parts storage for efficient

uman beings remain the key factor in determin the key uman beings remain ing a company‘s success – even as production digitized. Ex­ become increasingly processes agree. hibitors and visitors at the Hanover Fair makers and a driving force for more effective value effective more for makers and a driving force

- STEP 3: CONVERSION ASSISTANT

decision this may sound, whatever the However attractive creation. considerable and are of success – the challenges promises

OUT OF WORK OUT it is production, tasks in cigarette complex for responsibility people take Whenever new activities. Hauni’s routine invest in basic, the time they reduce necessary to BRAND CHANGE SMART TAKING THE STRAIN STRAIN THE TAKING In fact, the central theme of world’s most important indus In fact, the central theme of world’s

trial trade show this year was “Integrated Industry – Creating Industry – Creating trial trade show this year was “Integrated of the other things, this examined the role Among Value”. Industry 4.0 technol­ departments. employee in production solvers, into problem staff transforming production ogies are H

+ VISIONS + COMPETENCE 12

HiLiTE 1_17 HiLiTE COMPETENCE + VISIONS HiLiTE 1_17 15 ­ =

consuming, consuming, -

HiLiTE App house exhibition. “Approaches house exhibition. “Approaches - Oliver Matern, Manager at Hauni Project Watch videos with the new Watch for browsers and mobile devices. VR tantly, lies in finding the most efficient ways to deploy the ways to deploy the lies in finding the most efficient tantly, production in the Networked solutions human workforce. new opportunities for employees to express offer process chord with visitors to the in chord like these show our customers that we have understood going to become in the very just how smart factories are – and how we can make them smarter still. The near future of the workplace will not be defined by pioneering future machines alone – the key also, and perhaps most impor time their expertise by liberating them from monotonous or physically tiring tasks.” For Sören Witlake, For Sören of it was no surprise that the launch the Smart Brand Change system struck such a powerful We are always looking for ways to ways looking for always are We the work involved at each step reduce process.” of the production “

­ ­ ­ ­ ­ up tech - step through the entire conver the entire step through - by - ables him to simulate and plan the brand change. The The brand change. the plan and simulate to him ables ­ featuring illustrated labels. These contain the conversion the conversion featuring illustrated labels. These contain format change. for the operator requires which the units uses the planning tool to planner First, the production brand. This call the machine and select the appropriate nician uses the VISU to call up the conversion assistant, nician uses the VISU to call up the conversion assistant, instructions. This significantly sion with simple and precise to complete the the time and expertise required reduces in the components removed places the operator job. The Safely pack empty smart boxes. the in retainers moulded to the ware to be returned now ready aged, these units are house when the conversion has been completed. the machine at the requested time. Here, the set time. Here, the machine at the requested which guides him step en new for the boxes containing the conversion units required set of units brand and empty boxes for storing the previous they punctually to the location where can then be delivered planning system is connect needed. The production are ed to every other machine in the factory so it can quickly show the operator which one will need the least work for the specified brand change. By simply clicking a mouse, he a list of the smart boxes needed for the format then creates clerk. He assembles change and sends it to the warehouse with the in­ the full and empty smart boxes in accordance to and delivers them by the software structions provided The conversion assistant uses the VISU machine’s guide the operator to the through step-by-step process conversion entire with simple and precise instructions. - ­ ­ ­

house exhibition last November. house exhibition last November. - speed format change system for - Oliver Matern, Project Manager at Hauni Oliver Matern, Project end multifilter maker and presented it – together end multifilter maker and presented from standard standard from - of required warehouse stocks. A new solution for the world’s A new solution for the world’s stocks. warehouse of required the KDF 6MF LEAD fastest format change – developed for – now demonstrates the and tuned for maximum efficiency the first time. for potential of this approach sion instructions integrated into the machine’s VISU.” sion instructions integrated into the machine’s generates time savings of Perfect preparation 25 percent Just a few years ago, a complex format change including adjustment of length, diameter and segment length from quality to quality on a Merlin took 72 hours. And two em ployees would be working flat out. With the new KDF 6MF LEAD, the same job can be completed in just four hours. is the new Smart Brand Change system – with The secret aluminium smart boxes practical, stackable, waterproof, Innovative solutions liberate production employees Brand Change incorporates three elements: a software Brand Change incorporates three exchange and comparison brand for tool planning based box storage system parts identification, an aluminium smart with intuitive conver for the units and a conversion assistant Hauni developed the high its new high with the machine – at its in devel enthusiastic. “We was overwhelmingly The response to our customers’ response in Change Brand Smart oped increasingly becoming are changes Brand requirements. need a networked solution that so manufacturers frequent, sources eliminates and workload employees’ their reduces stops,” in unnecessarily long production resulting of errors at Hauni. “Smart explains Oliver Matern, Manager Project tasks and give them greater tasks and give them greater contribute their to freedom the production to expertise process. The holistic Smart Brand Change solu- Change Brand The holistic Smart innovative connects three tion cleverly system tool, storage modules: planning assistant.” and conversion “ ­ ­ ­ ­

potential for delivering the production efficiency gains his efficiency the production potential for delivering to the to seeking. “As a solutions partner customers are We production. take a holistic view of we bacco industry, where trying to find the points in these processes always are employees the time and effort reduce we can innovate and pos to achieve the best want We tasks. specific in invest and the by enhancing employee performance sible results quest for opti technological potential of machines.” Hauni’s much further than mization on behalf of its customers goes com systems or efficient more new, building and designing of the upstream ponents – it also takes account of processes such as focused organization and and filter maker, cigarette management advance planning of format changes including

+ VISIONS + COMPETENCE 14

HiLiTE 1_17 HiLiTE 16 HiLiTE 1_17 COMPETENCE + VISIONS WORLDWIDE HAUNI BORGWALDT GROUP, 2017 isaveryspecialyear for the is celebrating its150 measuring equipmentfor qualityassurance tobacco refinement andlaboratory and throughout theworld:Thespecialistfor tobacco smoke. as precision instruments for theanalysisoftobaccoand by addinglaboratoryandqualitycontrol equipment,aswell additives. Borgwaldtthengraduallyextendeditsportfolio ing businessasapioneerwiththedevelopment and aftertheSecondWorld War entered intotheemerg the companymovedtoBarmbekdistrictofHamburg in theHanseaticCityofLübeck.Around 60yearslater, Heinrich Borgwaldtfoundedaretail companyforfoodstuffs purposes. tobacco industryanditssub-suppliersforqualitycontrol leading suppliersofalldevicesandmachinesusedbythe in existingandnewmarkets.BorgwaldtKCisoneofthe tomized casingandaroma solutionsforsuccessfulactivity Borgwaldt Flavorsupportsthetobaccoindustrywithcus W HiLiTE Appforbrowsersandmobiledevices. You canfindfurtherinformationinthenew I t allstartedoff vices forcustomersfrom allovertheworld. nowadays coversawidespectrumofser Borgwaldt KC,thegroup ofcompanies ith its subsidiaries Borgwaldt Flavor and o n amuchsmallerscale:In1867, with its110 employees th anniversary. VR of tobacco

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Hauni Richmond,Inc. Hauni do Brasil Ltda. Hauni doBrasilLtda. Dickinson LeggInc. Borgwaldt KC,Inc. Hauni South Africa Hauni SouthAfrica Richmond Richmond Richmond São Paulo Hamburg Borgwaldt KC/FlavorGmbH Hamburg Hauni MaschinenbauGmbH Winchester Dickinson LeggLtd. Paris Decouflé s.à.r.l. Orléans Sodim SAS Pty. Ltd

Hauni Trading (Shanghai)Co.Ltd Company Limited,Shanghai Garbuio (Shanghai)Trading Wanchai -HongKong Konak /Izmir Ve Ticaret LimitedSirketi Hauni Teknik Hizmetler Treviso Garbuio S.p.A. Pécs Hauni HungariaGmbH St Petersburg OOO Shah Alam/Selangor Hauni Maschinenbau Hauni Maschinenbau Hauni JapanCo.Ltd Hauni FarEastLtd Hauni FarEastLtd HauniStPetersburg Hauni Singapore Hauni Singapore Hauni Malaysia Hauni Malaysia

Dubai Branch Singapore Sdn. Bhd. Shanghai Kunming Pte. Ltd GmbH Tokyo

for conventionaltobaccoproducts withthenextgeneration expanded ourproduct portfolioofaromas andequipment to ourcapabilityanticipatetrends, wehavesuccessfully the newtendencytowards reduced riskproducts: “Thanks ket with its departure from the conventional cigarette and company welcomethehighdynamicsofchangeinmar flexibly.” Themanagingdirectors ofthelong-established trends atanearlystage,thusenablingustoreact to them porate activities.Thisputsusinapositiontoidentifymarket the factthat“thecustomerisalwaysfocalpointofallcor Briel, ManagingDirectors, largelyputtheirsuccessdownto control andtobaccorefinement. Marc NarugaandAndreas in thefieldoflaboratoryandmeasuringequipmentforquality to theHauninetworkandisnowgloballeadingsupplier For justoverfouryears,theBorgwaldtGroup hasbelonged Aygün studiedmechanical engineeringandhas Managing Director forHauni inTurkey. Cem OsmanAygün tookoverthepositionof New ManagingDirector inTurkey: InAugust, of solutionsinthenewreduced riskproducts sector.” more than15yearsofprofessional experience in theautomotive,automation,machineand thermo-technical systemssectors.

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COMPETENCE 17 HiLiTE 1_17 HiLiTE COMPETENCE + VISIONS + VISIONS

COMPETENCE FACTS & FIGURES

New control system for BOB-M

Hauni is offering an upgrade to the BOB-M bobbin changer as TIP L MH 150. This incorporates the latest version of a Beckhoff control system with extensive options for meeting special customer requests. The upgrade contains the Hauni VISU+, which simplifies operation of the BOB-M. State-of-the-art technology is applied to reduce future difficul- ties in obtaining spare parts. In addition, the new guard system meets the highest safety standards. In summary, this TIP guarantees an improved performance for faster bobbin discharges and charging operations.

Tobacco reclaiming unit

As part of the process, loose tobacco is fed into the pro­ duction waste along with other products whenever the machine is started and stopped. Conventional recovery during the process is difficult and time-consuming – which is why Hauni has now developed a waste separation unit with automated refeeding for the PROTOS M generation. Available as TIP C SE 577, it reduces the operator’s workload, separates tobacco from other waste, prevents additional tobacco degradation and returns tobacco Exhibition at Decouflé in Paris directly to the machine in metered quantities.

auni subsidiary Decouflé is inviting the inter­ of filter tube make/pack and its machines for cigars and national tobacco industry to a three-day in-house cigarillos. “The exhibition is also an opportunity to inform cus­ exhibition at its Paris headquarters – immediately tomers about the new one-team approach. This allows us prior and after to InterTabak in Dortmund. From to combine the best of both worlds: on one hand, the huge E-Kit for KDF 3/3E H21-22 September 2017 and on 25 Sep­tember 2017, the com­- global decentralized Hauni Sales & Services network and, pany will present the latest innovations from its product range, on the other hand, the excellent know-how of the Decouflé HAUNI OFFERS TIP F KD 500 TO COUNTERACT the effects of which focuses on the efficient manufacturing of cigarettes, product management team. We have a lot to report in this obsolescence in the area of control and drive systems, visualization filter tubes, paper filters, cigars, cigarillos and reclaiming. area. The adaptations we have made allow us to concentrate components, pneumatic control units, data processing and sensor Decoufléc an look back on a long and successful history and on growing our business and portfolio in new and existing technology. This provides replacement of all electrical components has been supplying individual niche products to the tobacco markets,” explains Nicholas Müllem, Managing Director of for the KDF filter maker. The upgrade has a wide range of positive industry for 150 years. The specialist is renowned for its smart, Decouflé. The first results of this development will be demon­ effects on quality, energy consumption, footprint, brand management, easy-to-use technologies and services. The insert on page 18 strated live during the in-house exhibition in September. = operation and maintanance. HiLiTE 1_17 HiLiTE provides an overview of the company’s solutions in the areas

HiLiTE 1_17

19 18 20 HiLiTE 1_17 CHALLENGES + SOLUTIONS with HauniChina,thebestismadejustthatbitbetterhere. production facility inthecentre of oneof theworld’s largest metropolises. Together THE SHANGHAITOBACCOGROUPCO.LTD (STG) WORLD-CLASS LEVEL OPTIMIZATION ONA operates astate-of-the-art cigarette S consulting project aiming to achievestabletobaccocon- isn't scared off bythis prospect. They have developed a General ManagerServicesHauniChina.Buthisteam doesn’t actuallymakeourtaskeasy,” saysMarco Castro, “The world class levelat which cigarettes are produced here Consistently reduced waste here thatcanstillbeimproved? sive production that runs like clockwork. Is there anything est tobacco manufacturers in the world, operates an impres- dust intheair. TheShanghaiTobacco Group, oneofthelarg anywhere; everythingisperfectlycleanwithnoperceivable adjust thesettings.There isnoresidual tobaccotobe seen all processes, cleanthe machines whenever necessary and the Shanghai Cigarette Factory (SCF). They keep an eye on thing runssmoothlyonthe18PROTOSlinesbelongingto produced in2016.Skilledemployeesensure that every a heightofthree metres. More than74billionstickswere conveyor beltsthatwindtheirwaythrough thevasthallat One red cigarette packetstandsnexttoanotheronsmall cigarette waste. machines andavalidroot causeanalysisfordeviations in able totheexperts,enabling a meaningfulcomparisonofthe analysis: Largequantitiesof data andinformationare avail such factoryintheworld,whichproves invaluableforexact identical HauniPROTOS-M5makers.There isonlyone produces thesamecigarette brandonanastonishing18 The specialfactoristhattheShanghaiCigarette Factory percent ofcigarette wastefrom thePROTOSlines. Stability Analysis”(CSA).Theambitioustargetisastableone rette waste.Theproject bearsthename“Consumption sumption bymeansofaconsistentlyreduced levelofciga quietly andquicklyonthePROTOS-M5machines. mium brandinChina,are manufactured extremely high-gloss floor. “Chunghwa”cigarettes, apre tainless steelproduction machinesreflect inalight ­ - - - -

“ actually make ourtaskeasy. ” cigarettes are produced here doesn‘t Marco Castro, GeneralManagerServices HauniChina The world-classlevel atwhich

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CHALLENGES CHALLENGES 21 HiLiTE 1_17 HiLiTE 22 HiLiTE 1_17 CHALLENGES + SOLUTIONS cellent quality,” saysZhou.“Haunihelpsustodojustthat.” only strivetobehighlyefficient, butalsowanttoprovide ex and consulting strategy. “We benefitfrom that,as wenot plier, asithasalsodevelopedacomprehensive services Group. Hauniissomuchmore thanpurely amachinesup Zhou Yongsen, President Vice oftheShanghaiTobacco together withtheoriginalequipmentmanufacturer,” says that we are on the right path by working on optimizations and systemsforthetobaccoindustry. “We are convinced skills asthegloballeaderinmanufacture ofmachines eral ManagerCastro. Ontheotherside,Hauniisaddingits of qualitycigarettes onPROTOS-M5makers,”saysGen an extremely highlevelofcompetenceintheproduction that characterizesthemintheirrespective field.“SCFhas Here, twopartnerscontributetheoutstandingexpertise Hauni asanimportantadvisor Vice President oftheShanghai Tobacco Group: Both sidesmustbenefitfrom theaddedvalue. One thingiscleartoZhouYongsen, - - - change. According President toVice Zhou,theShanghai in Chinatoo,ashealthawareness risesandsmokinghabits is enormous.Smokingbansare beingincreasingly enforced The pressure oncigarette manufacturers allovertheworld for 24years. continue toimprove”, saysJiao,whohasbeenwithSTG that theproduction processes remain stableandthatwe worldwide. Now, togetherwithHauni,wewanttoensure maker. “We knowthatHauniproduces thebestmachines Hauni new factorysixyearsago,itdecidedonthemodern processes machinery. – and modern When STG built the employees capableofoptimallymanagingtheproduction priority.” Theproduction ofagoodcigarette requires skilled to deliveroutstandingproduct quality. “Qualityisourtop the absoluteaspirationofShanghaiCigarette Factory Jiao Xi,Director ofChunghwaWorkshop, alsoemphasizes Optimally managingprocesses

square metres insize. 18 PROTOSlines The production hallwiththe is 125,000

Shanghai Cigarette Factory, In thespeciallyarrangedproject room atthe Nicholson discussthelatestmachinedata. of ChunghwaWorkshop, VikkiLuandKeith possible. Thecostsofoptimizationmustnotexceedthe approach. Thismeansthatexpenditure iskeptaslow geous. Indoingso,Haunipursuesa“minimumnecessary” processesinternal from theoutsideisextremely advanta Hauni teamonboard tosupportus,”saysJiao.Theviewof requiring stableprocesses. “We are pleasedtohavethe at anoptimalbalancebetweenqualityandwaste,agoal resulting inincreased tobaccoconsumption.STGisaiming of highqualityalsomeansalevelrejects, inturn petitive. However, inmanycases,ahighproduction volume still deliveringatop-qualityproduct canSTGremain com Only byincreasing productivity andreducing costswhile Efficiency iscalledfor ing todemands. customer behaviouranddeveloping products correspond Tobacco Group isfacingthechallengeofprecisely analysing Jiao Xi,Director - - - “ goal here wasconsistentandvaliddata collection.Thein lected round the clockon18machines in three shifts.The levels andfrom variousdepartments.Machinedatawere col- At SCF, 40employeesare involvedintheproject at different stable machinesistheonlywaytoreduce waste.” processes and to subsequently monitor them. “Operating important tofirstdefinetheoptimalmachinesettingsand and ManageroftheProject CSAshares thisopinion.Itis Factory DirectorVice of the Shanghai Cigarette Factory higher-level factoryprocesses”, saysCastro. LiuGuoping, bility isachieved,canoptimizationsbeconsidered thataffect are establishedfortheindividualmachineandareliable sta successful production operations.“Onlyifqualityprocesses the Hauniexpertsconsiderthisanessentialprerequisite for Furthermore, thestrategyistoproceed from bottomtotop– Bottom-up approach tomer allthingsconsidered. expected benefit,asthatwouldmakenosensetothecus Jiao Xi,Director ofChunghwaWorkshop on board tosupportus.” We are pleasedtohave theHauniteam

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CHALLENGES CHALLENGES 23 HiLiTE 1_17 HiLiTE 24 HiLiTE 1_17 CHALLENGES + SOLUTIONS “ Marco Castro, GeneralManagerServicesHauniChina treats thedatawithinproject.” with whichShanghaiCigarette Factory We verymuchappreciate theopenness jointly assumedtheproject managementtoensure thatthe ty andopencommunication.LiuGuopingMarco Castro Castro. Thecooperationasawholeisbasedontrust,hones ness withwhichSCFtreats thedatawithinproject,” says pie and other charts. “We very much appreciate the open project room atSCFwere plastered withdatasheets,graphs, with the Hauniexperts. The walls in the specially organized formation wasthenjointlyanalyzedanddiscussedtogether processes and the management in the tobacco industry and Hauni China,hasanexcellent knowledgeoftheproduction Lu,Deputy GeneralManagerServices for allinvolved.Vikki agree that this willnot work without a “changeof mind-set” this cooperationalsoposesagreat challenge.Bothsides one anotherandbenefitfrom the respective counterpart,but good teamworkbetweenHauniandSCF. Both sides respect “One plusoneismore than two,”saysJiao,emphasizingthe Cross-border cooperation coopera tion workswellonalllevels. ­

processes even further. they are aimingtoimprove the the supportofHauniteam, sive practical knowledge. With Cigarette Factory The employeesoftheShanghai - - manpower, know-howandgreat commitment oftheteam. in advance,thusacknowledgingthehighresources input, customer hasplacedagreat dealofconfidenceinHauni mized cigarette Luadds.Here, manufacturing,” Vikki the factory. Onlybymutualcooperation can weachieveopti ists, thecustomerisactualexpert,asheoperates have understoodthatalthoughweare themachinespecial The entire project process isalsoalearning forHauni.“We methodology forthisanalysis,”Marco Castro reports. out a data analysis on this basis. “We developed our own closely withtheSCFmembersofproject whilecarrying collected data andthe data selection,and communicated from Haunisystematicallycheckedanddocumentedthe A totalof15engineers,technicians,analystsandstrategists and conceptdevelopmentoftheCSAproject. Vikki Luisco-responsiblealso confirmsthis. forthestrategy have exten- - - “Technical Consultancy Report” oftheCSA project. Florian Mirus(from lefttoright)handingover the Zhou Yongsen, LiuGuoping,Marco Castro and A big day for the team: A bigdayfortheteam: ogy intermsofhowtoputour improvement proposals into roadmap andare now developing atailor-made methodol- tested ontwoPROTOS-M5 machines. “We havecreated a and Man.Theidentifiedimprovement potentialisnow tobe Focus wasplacedonthe“three Ms”–Machine,Method in shiftoperation,alwaysbearingthecigarette wasteinmind. chose fourofthemachinesandcompared theirperformance To findthecauses ofthedeviations,Haunispecialists ed atthe18examinedPROTOS-M5machines. Despite this,differences inconsumptionstabilitywere detect effective. Establishedprocesses ensure shortresponse times. tween themanagementandemployeesatmachine is Shanghai Cigarette Factory are high,andcommunicationbe output and waste. The process management standards of the generally achievegoodresults intermsofefficiency, quality, sis to the customer. Thisreport establishes that the machines Consultancy Reportandwithittheresults ofthestabilityanaly In themiddleofFebruary, HaunihandedovertheTechnical Machine deviations

­ - - end isthatbothsidesbenefitfrom theaddedvalue. the project brings”saysZhou. Becausewhatcountsinthe next steps.“We wanttocontinue toimprove andseewhat President Zhoualsoviews thereport asagoodbasisforthe Shanghai Tobacco Group asacooperationpartner.” Vice reproducibility. “Infuture, wewouldliketoaccompanythe achieved bymeansofcontinuouscontrol, monitoringand beginning ofalarger-scale project. Long-termstabilityisonly sees the“ConsumptionStabilityAnalysis”report asonlythe Florian Mirus,ManagingDirector ofHauniFarEastLtd.,also Added valueforbothsides customized methodologyforthispurpose. of thisstability,” saysCastro. Hauniisalsoabletodevelopa ity, buttheactualchallengeliesinlong-termassurance lines. “We are convincedthatourroadmap will ensure stabil lection ofwaste-related real-time dataonthe18PROTOS dardization onallmachinesasabasisforthenecessarycol Cigarette Factorytoperformasoftware updateand stan from theR&DdepartmentinHamburgvisitedShanghai practice,” Castro reports. InFebruary, twoHaunicolleagues VR HiLiTE Appforbrowsersandmobiledevices. Discover morephotoswiththe new

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CHALLENGES CHALLENGES 25 HiLiTE 1_17 HiLiTE CHALLENGES + SOLUTIONS HiLiTE 1_17 27 -

using VR technology. technology. VR operations VR operations Also interesting Also interesting urban planners: can be optimized can be optimized give surgeons the give surgeons just next to them. just next ity fields by 2020. Be it development, production or production development, it Be 2020. by fields ity at many maintenance, the technology can be profitable the For example, before points in industrial processes. builds a cruise in the Emsland region Meyer shipyard virtual look into the machine it takes a precise liner, to detect possible sources or laundry in order rooms potential and initiate any identify optimization of error, actual construc- before measures necessary remedial tion begins. also test the first prototypes Automotive manufacturers prior to construction to establish what the newly devel- assembly. later of terms in mean actually ideas oped Using a VR tool, they virtually assemble the compo- nents and find out whether the employees at the as sembly line can implement the planned measures. tients, rather than tients, rather for architects and for architects Building processes Building processes ing inside their pa- The endoscope as The endoscope as the surgeon‘s eye: the surgeon‘s eye: impression of work- impression

------hanks t hey are part of events hey are t iewers can look around in real time in real iewers can look around V rtual Reality (VR) replaces the real world the real rtual Reality (VR) replaces i with a virtual one, both visually and acous tically. and feel as if n addition to pure VR, there are also mixed are VR, there n addition to pure I V to the high display resolution and high-quality 3D to the high display resolution images. extend humanReality that forms such as Augmented This means that virtual information, perception. reality faded into the real animations or graphic elements are human field of vision. applications Versatile of predominantly While the new technology was initially its advantages for train for computer games, interest evident. ing and educational purposes soon became in a virtual environ operation Pilots can practice aircraft ment, and captains can perfect the art of manoeuvring their ships. Physicians have the opportunity to digi that this works, a ensure tally simulate operations. To using is created patient the model of three-dimensional imaging, magnetic resonance computer tomography or op thus enabling the physician to safely test the entire than more the medical aspect offers eration. However, endoscopy, just planning and training. Millimetre-based now can operations, during used increasingly is which to the VR its images with tiny cameras directly project glasses of the physician, thus giving him or her the inside the patient. The of moving directly impression line to connected by control surgical instruments are special data gloves worn by the surgeon. number of industrial companies also An increasing a study of to According technology. VR of use make German compa the Deloitte Consultancy Company, in innovative nies wish to invest just 850 million euros the Virtual Reality and Mixed Real- applications from

REALITY. VIRTUAL

SEEING THINGS FROM SEEING THINGS A NEW PERSPECTIVE Computer gamers aren’t the only ones living in aren’t Computer gamers urban by long been exploited have The possibilities it offers and industrial companies. professionals medical planners,

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HiLiTE 1_17 HiLiTE 28 HiLiTE 1_17 CHALLENGES + SOLUTIONS ers ortraffic expertstooptimizebuildingprocesses, planners, project developers, architects, building own- into theworldofvirtualreality. This enablesurban equipped withVRglasses,youcandiveheadfirst Fraunhofer InstituteforIndustrialEngineering.Here, reo projection room in Germany. It is operated by the open upinperfectiontheonlyfullyimmersiveste wander through wholenewworlds.Theseworlds tors simplyputonVRglasses,enablingthemto biggest products andmost complexsystems.Visi tions giveexhibitorsthepossibilitytopresent the Realityapplica- When usedattradefairs,Virtual in linewithmore efficient andprecise systemplanning. check materialflowstogetheroroptimizework parks oftheircustomerstruetoscale.Theycanthen builders canvisualizetheirsystemsinthemachine totypes are required. Usingthistechnology, machine in laterproject stages,asaresult ofwhichfewerpro - This savestimeandcosts,asithelpstoavoidchanges Training inextended reality: virtual worldare combinedintoamixed reality. technologies, thereal physical worldandthe With theappropriate

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es or“smartglasses”functioninadifferent way. They Augmented reality glasses,alsoknownasdataglass is generated. wearer, thesenseofmovingdirectly inthevirtualworld head. Asthedisplayfollowsheadmovementof headsets andsensorsthatrecord movementsofthe display that covers the entire field of vision, they have glasses isalsowelladvanced.Alongwithanear-to-eye dimensional worldsinreal time.ThetechnologyforVR things, andspecialsoftware calculatescomplexthree- ated using360-degree photography, amongstother more established.Suitableimagematerialcanbecre Technology forvirtualreality isbecomingmore and Viewing technologyisdeveloping they are standinginsidetheplannedbuilding. give planningteamsandcustomerstheimpression that jectors fillaprojection area of300square metres and cities overa360-degree projection area. Sixlaserpro- depiction ofmachines,factoriesorevenentire townsor a mixedreality laboratoryusedbycompaniesforthe hofer InstituteforFactoryOperationsandAutomation, At leastasspectacularisthe“Elbedome”ofFraun simulate traffic projects. tectural visualizations,walkthrough virtualbuildingsor the required tools,partsorworkstepsintotheworking maintenance work,amongstotherthings.Theyfade Such smartglassesare the toolofchoiceforcomplex without screening himorheroff from theoutsideworld. virtually project informationinfront ofthewearer’s eye, make residential area concepts visible, perform archi environment forthetechnician.

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VR solutionsalsooffer excitingpotentialforuseintrainingcourses.” us whenwevisitcustomersandgivethemacompletetourofthemachine–quiteliterally. Naturally, independently oftheirlocation.Forexample,theapplicationenablesustotakeatobaccocutterwith ited totradeshows.“TheadvantageofVRisthatitallowsuspresent oursolutionstocustomers For HelgeLampe,HauniProject Manager, thepotentialofnew VRtechnologyisinnowaylim- KT 3tobaccocutterinacompletelynewway. reality system,visitorswere abletoexplore theHDT3Esuperheatedsteamdryerand that fittedinperfectlywiththethemesof“Innovation”and“Industry4.0”.Usingavirtual be quiteachallengeuntilitfoundsolutionatitsin-houseexhibitionlastyear–anidea As manyofHauni’s Primaryplantsare toolargetobeexhibited,Haunihasfoundthis In essence,atradeshowisalwaysanopportunitytointroduce visitorstonewproducts. mations togiveusersabetterunderstandingoftheprocess. using theflowdryingprincipleandelectricalheatingwith ani- Hauni combineda360° model oftheHDT3Etobaccodryer VIRTUAL REALITY VR for browsersandmobiledevices. Enjoy avirtualtourwiththenew HiLiTE App HiLiTE App AT HAUNI visitors couldexplore first-hand. recreated asafull-size,virtual,interactive3Dmodelthat the newknifesharpnesssensor. Thewhole machinewas KT 3tobaccocutter In addition,Haunipresented thelatestgenerationof together with – for the first time – together with–forthefirsttime

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CHALLENGES CHALLENGES 29 HiLiTE 1_17 HiLiTE CHALLENGES + SOLUTIONS HiLiTE 1_17 31

- - - = . launched in Japan their latest product launched in Japan their latest product in this category – Ploom TECH, which for many years. In 2016 the company combines the best of both tobacco involved in heated tobacco products involved in heated tobacco products tech “Ploom TECH’s and e-cigarettes. Japan Tobacco Group has been actively Group Japan Tobacco nology is revolutionizing the category nology is revolutionizing Next Generation Products at BAT. at BAT. Next Generation Products and, based on our current data, we believe and, based on our current said Kingsley Wheaton, Managing Director said Kingsley Wheaton, Managing Director Emerging Products. President has the strong potential to be a reduced-risk potential to be a reduced-risk has the strong and launch of Next Generation Products,” and launch of Next Generation Products,” product. We plan to continue its expansion We product. further”, said Yasuhiro Nakajima, JTI’s Vice JTI’s Nakajima, Yasuhiro said further”, the last five years in the development, scale-up ment program. BAT has invested over US$1 billion in BAT ment program. and experts following an extensive research and develop and experts following an extensive research use a battery-powered external energy source to heat the external source use a battery-powered energy as a solutions partner in “Hauni has been involved product. to date,” reports the development of all the existing platforms Patrick Fricke, Head of Marketing at Hauni. per 180 percent at around With growing the market currently devel- HNB in invested being is money of deal great a year, €500 approx. opments. PMI, for example, has spent million of scale production on its first manufacturing facility for large “Our ambition two heated tobacco alternatives cigarettes. to that non-combustible to ensure is to lead a full-scale effort to the benefit of adult cigarettes ultimately replace products said our company and our shareholders,” smokers, society, Officer. Chief Executive Calantzopoulos, PMI’s André pow began selling iFuse – its first HNB product In 2015, BAT battery – in Romania. At the end of by a rechargeable ered This new product 2016, it also launched the glo™ in Japan. toxicants byheats rather than burns and reduces tobacco 90%. “glo™ has been developed by our leading scientists ------ON MORE THAN THREE DECADES OF EXPERIENCE ON MORE THAN NOT-BURN - ore than 20 years ago in 1996, Reynolds launched than 20 years ago in 1996, ore which the Eclipse – a heat-not-burn product (HNB) health towards The trend is still in the shops today.

a sector in which Hauni can draw in which Hauni can draw a sector Almost no other area of the tobacco industry is growing as dynamically as “heat-not-burn” – “heat-not-burn” as dynamically as is growing industry the tobacco of area Almost no other ier lifestyles and more extensive regulations for tobacco prod regulations extensive ier lifestyles and more once niche mar world have transformed this the ucts around are All the major manufacturers ket into a booming sector. heated rather merely which are developing tobacco products reducing the level of harm significantly than burned, thereby ful substances contained in the smoke. and development by market partici Investment in research into an old idea. And the new so new life pants has breathed accept aim to achieve widespread lutions they have created two main types of HNB ance among smokers. Essentially, solutions are The first group available today. platforms are Philip from Teeps such as the familiar Eclipse and the new lit are Morris Internationallook like cigarettes, (PMI). These The second group no external supply. energy and require new developments such as Heatsticks for the iQOS from are which PMI or Neosticks for the glo™ made by BAT, HEAT M

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HiLiTE 1_17 HiLiTE 32 HiLiTE 1_17 CHALLENGES + SOLUTIONS In 2016, SPARE PARTS FULL SERVICE FOR This canreduce stocks of spare partsby upto 40percent. the tobacco industryto offer afull-servicespare partssupplysolution. HAUNI LAUNCHEDVMI+ and thusbecamethefirst supplierin L of spare parts.” reducing capitaltiedupinmaintainingstocks duction runssmoothly available on-siteatalltimes.It guarantees thatallnecessary spare partsare Using Hauni’s ad-hoc supplyasabackbone,it this directly ensures optimizationofstocks. tion with an enhanced ment solutionforspare parts.Inconjunc to create abespokesupply chainmanage history andindividualproduction parameters with thecustomer’s specific requirements We takethisunderstanding andcombineit tise andexperience in supplying spare parts. This base ofsome600factoriesaround theworld. customer isobvious. “We havea customer VMI+ has been sucha success for the first Manager ServicesatHauni,thereason why planning phase.ForClausPeters,Group ther European factoriesiscurrently inthe Germany. Theroll-out in around 10fur g ives usanunparalleledlevelofexper tion plant of a leading company in tion plantofaleadingcompanyin the prototype ofVMI+intheproduc- a st year, Haunisuccessfullyinstalled while simultaneously whilesimultaneously r eordering point, e nsures t hat pro- - - - -

workload inpurchasing departments:“We same time,thefull-serviceoffer easesthe also reduce “out-of-stock”events.Atthe can notonlyoptimizecustomerstocksbut targeted VMI+analysisalgorithms,Hauni dependence on“safetyfirst”thinking.Using corporatestructuresestablished internal and plant warehouses are therefore areflection of total. Thestocksmaintainedinproduction machine coverwellabove98percent ofthis the spare partsrequired foreachproduction of percent plannable 35.4 requirement. And cent ofspare partsmakeup95percent ofthe production machine, an average of 9.2 per highlights thepotentialsavings.Foreach An analysisofHauni’s extensivedatabase - Hauni performs a free analysis ofhistorical spare cesses issimpleforHauni customers.First, Integrating VMI+into stock management pro lack ofkeyspares,” explainsPeters. nates theproblem ofdowntimecausedbya through our supply program. It completely elimi- then guaranteeavailabilityofcriticalspare parts We agree thescopeofsupplywiththemand and procurement onbehalfofourcustomers. take responsibility forevery area ofplanning Higher availab capital empl for browsersandmobiledevices. Explore 360°viewsusingthenew with value less Reduction in in stock oyed ity ility

Stock value

Items HiLiTE App HiLiTE App - – andthatstartswithcustomer-friendly imple dom toconcentrateontheircore businesses try. Inprinciple,itgivesourcustomersthefree point product ofitskindinthetobaccoindus ethic. “VMI+istheonlydynamicreordering is thesystematicimplementationofservice and programs theinterfaces.ForPeters,this in thecompany’s needs.ThenHauniconnects can becontinuouslyadjustedtomeetchanges to definethe required scopeofsupply, which part consumptionandworkswiththecustomer mentation,” heexplains. VR STOCK VALUE CTION REDU

Stock value

Items

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CHALLENGES + SOLUTIONS HiLiTE 1_17 35

- bution length of 1,100 mm. with the new SE-M efficiency The team also improved zone and formation which has a longer rod maker, rod high-end technologies and developing completely new and developing completely new high-end technologies feeder is the heart of the machine. components.” The in the used process adopted the Hauni example, for Here, and on the suction shaft process VE-M8, which is based to process the best way This is currently two fluidized beds. sepa- zigzag a functionality with large extra The tobacco. an output of 20,000 cpm. It ensures rator is suitable for on the suction tape formation even tobacco rod extremely of 12,000 cpm at the for the PROTOS-M5e with an output and a distri speed of 6,000 cpm per rod process reduced the feeder to the filter assembler,” explains Jens-Dieter Jens-Dieter explains to the filter assembler,” the feeder using Consultant at Hauni. “This included Schmidt, Product

- olution describes the process of gradual change change of gradual the process olution describes v or enhancement of specific and the development So generation to generation. characteristics from PROTOS-M5e efficient the “e” in the new ultra-high could equally stand for evolution. This innovative machine for evolution. This innovative machine could equally stand of generation of the PROTOS-M series is one of the next of the development potential makers and demonstrates years old. All successful range, which is now twelve Hauni’s in- reliability, quality, outstanding offer makers M-generation With the new PROTOS-M5e, flexibility. vestment security and capable of machines are Hauni has shown what premium to and focus on their cus today when developers respond efficiency. for maximum tomers’ desire the PROTOS-M5e, we aimed designing “When we were from system in the point at every maximum efficiency for E

fast & powerful & fast – the world’s most efficient most efficient – the world’s

PROTOS-M5e EFFICIENCY FOR FOR

cigarette maker for the 12,000-cigarettes-per-minute sector. sector. the 12,000-cigarettes-per-minute for maker cigarette Hauni presents the new the new Hauni presents e

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HiLiTE 1_17 HiLiTE 36 HiLiTE 1_17 CHALLENGES + SOLUTIONS intuitive intuitive reliable & designed to eliminate operating errors. Simple illus- Every aspectofthePROTOS-M5e trations onthemachine assisttheoperator. has been

drum –isagreat benefitin thisarea. carrier, transferunit,trimmer, oil-free printerandseparating variety ofpatentedHaunitechnologies–suchastheknife is muchsimplerforthepersonnelinvolved.Theuseof a reducing theamountofwork required. Maintenanceitself oil-free. Thisincreases maintenanceintervalswhilealso need forgearunitsandthemachineis,firsttime, end mechatronic concept. Individualdriveseliminatethe maintenance timeandcostsbyimplementinganend-to- Hauni’s developersmetthegrowing demandforreduced approach toeliminatingerrors. tions usingmandrels. Thesemeasures takeasystematic setup usingascaleandsimplifiedinsertionoftransferposi adjust thepaperguidesystem,universalseparatingdrum illustrated instructionlabelsexplainingthecorrect wayto to trainnewoperators.Forexample,themachinefeatures tential foroperatingerrors butalsocutthetimerequired has simple,intuitivecontrols thatnotonlyreduce the po plemented theseinthenewPROTOS-M5e.”Themachine for operatorerrors whenadjustingsettings.We have im- mated machinehandlingsystemsthatreduce thescope Schmidt. “Thesecurrently includeadesire forhighly auto we haveidentifiedademandinthemarket,”continues in thiscaseefficiency –andinnovativeconceptsforwhich PROTOS-M5e, wealwayslooktointegratespecificideas – “When wedevelopanewflagshipproduct likethe Optimized atourcustomers’request end andmuchlesswaste.” and centrifugalforces. Asaresult, itgenerateslessloose revolution. Thelowerspeedminimizesthemechanicalload more densely so more cigarettes can be transported per ports Jens-DieterSchmidt.“Thecigarettes are arranged than instandard machinesforthe12,000cpmsector,” re the new MAX, the processing speed is 20 percent lower MAX-M filterassemblerboostsproductivity stillfurther. “In other commoncausesofmachinestops.Thebrandnew significantly turn reduces thenumberofburstseamsand therefore provides more time for forming the rod. This in ­ - - -

... integrate sensorsandqualitycontrols forexistingorfuture ample, expansionunitsgivemanufacturers theflexibilityto suitable forusewithinnovativefuture processes. Forex- ment, Haunipaid attention to ensuring themaker would be security.” Duringeverystageofthe machine’s develop requirements. Asaresult, itoffers outstandinginvestment already meetsallpresent andfuture high-techproduction duction processes andincrease process transparency. It which provides allthetoolsneededtooptimizepro sors andcanbeconnectedtotheAREOsoftware suite, tantly, thePROTOS-M5emakerisavailablewithsmartsen Remote Servicecapabilityasastandard feature. Impor explains Jens-Dieter Schmidt. “We have even integrated components foracquiringlargevolumesofreal-time data,” with all the necessary interfaces and the latest electronic ready forIndustry4.0.“Thecigarette makerisequipped Like allnewmachinesfrom Hauni,thePROTOS-M5eis Bring onthefuture the maker alsooffers excellent flexibility. As wellasahighlevel ofadaptability, smart &economic

- - - - name alsostandsforeveryformofefficiency.” specified level of output,” reports Schmidt. “So the ‘e the machineconsumesminimumenergyrequired forthe ply anenergymonitoringsystemforthemakertoensure that ingly importantarea ofenergyefficiency aswell.“We cansup the PROTOS-M5e offers significant potential intheincreas 90 to95percent andreduced waste byone percent.” And same time,wehaveincreased theefficiency ofthe maker from to justtwohoursfrom qualitytoquality,” saysSchmidt.“Atthe cut thetimeneededforaQuickSizeChange(QSC)from 2.5 automation andreducing thenumberofparts,wewere ableto also offers excellentflexibility. “Byachievingahigherlevelof foration unit.Aswellasahighlevelofadaptability, themaker for use with additionalinterfaces, e.g. forasecond laser per processes atalaterdate.ThePROTOS-M5eisalsosuitable The oil-free spider operational safetyof themachine. be pinnedfor easy operation andincreases the on thetransfer drumcan

’ in the =

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37 HiLiTE 1_17 HiLiTE 38 CHALLENGES + SOLUTIONS Web formation process Conditioning Paper machine fibres Tobacco HiLiTE App Watch fascinating animationswiththenew

VR for browsersand mobiledevices.

tobacco residues Dust, stemsand

Extraction Water e.g. nicotinearoma Soluble portion, tobacco Reconstituted Size press Evaporation

S TOBACCO MATERIALS investment isachievedinaround oneyear. cigarette rod. of FortheSheet Xsolution,thereturn to 97percent ofSheetXproduct isretained inthe ed, itcaneasilybeusedincigarette makersandup As thefinishedSheetXproduct hasbeenexpand of investmentisachievedinaround oneyear. the cigarette rod. FortheSheetXsolution,return rette makers,withupto97 percent beingretained in The finishedSheetXproduct iseasilyusedinciga ready formixing,flavoring andfeedingtomakers.” and cutbefore beingadded tothefinalblend– starch. Theextrudedthin strands are thenflattened 60 percent sievedtobacco withupto40percent Director ofGarbuioDickinson.“Thisprocess mixes the ragblend,”explainsMarkAldridge,Managing easy-to-operate solutionforutilizingtobaccodustin customers onalimitedbudgetspace-savingand oursolutionforSheetXproduction, weoffer“With viable processes. has launchedinnovativesolutionsforallthecurrently paper. Overthepastthree years,theHauninetwork HNB products primarily useslurry/ cast sheet and nique fortransformingwastetobaccointopaper. The third optionisthehighlysophisticatedtech and scrap into slurry for manufacture of cast sheet. and more complex method processes tobacco dust technologies. The simplest is extrusion.Thesecond (HNB) has given fresh impetus to the use of these The recent trend towards products heat-not-burn ment inthe The Hauninetworkoffers technologieswhichmeetevery customer require- REUSED an importantarea forgeneratingsavings. tobacco foruseintraditionalcigarettes as facturers haveviewedprocessing waste ince theearliestdaysofindustry, manu PROCESSING OFWASTE TOBACCO/DUSTINTOALTERNATIVE – from extrusion to slurryandpaper. TOBACCO TOBACCO - - - - tobacco wasteintoavarietyofvaluablematerials. tobacco paper–Haunitechnologiescantransform paper in terms of nicotine content, sugar level and paper intermsofnicotinecontent, sugarleveland process andprecisely adjustthecomposition ofthe to return upto100percent ofrecon tothePrimary with excellentproduct quality enablesmanufacturers explains Aldridge.“Highproduction capacitycoupled taste, chemicalproperties andmoisture content,” ducing logisticscosts.“Manufacturers canalsotune facturer. Thisincreases flexibilitywhilesignificantly re- scale thatiseasytohandleforeverycigarette manu bacco paperfrom dust,stems andscrapsonasmall only manufacturer tooffer asolutionformakingto- can manufacture thismaterial in-house.Hauniisthe co tospecialistfactoriesaround theworld.Nowthey paper recon usuallysenttheirstocksofwastetobac sector. Until now, manufacturers requiring tobacco processes recon intoproducts foruseintheHNB Hauni networkhasalsolaunchedaninnovationwhich In additiontoasolutionforslurry/castsheet,the flavor atanytime.” A wealthofrecon products

Sheet-X, slurry/cast sheet, Sheet-X, slurry/cast

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SOLUTIONS 39 HiLiTE 1_17 HiLiTE CHALLENGES + SOLUTIONS HiLiTE 1_17 41 T R E Q w W

coal coal coal + Recess

obacco + Colour ca Hollo Acetate + char Hollo capsule + char acetate + char charcoal Acetate + t char 1. Triple filter: 1. Triple filter: 2. Triple actetate vity +white ed whiteacetate+ 3. Dual filter: + w +thread filter: 4. Triple 5. Quadruple filter: w shape+ filter: 6. Triple coal +paper

to materials used in every current application. It ensures the application. It ensures materials used in every current – is perfect for an maker – which is completely oil-free tasks.” and future enormous range of current Focus on format change an with solutions demanding constantly are Manufacturers developers the response, In flexibility. of level greater ever which en- systematically integrated Hauni LEAD technology, ables the length and diameter format to be changed faster the modu- from – machine the throughout before, ever than “In the basic configuration, maker. lar drum section to the rod quality conversion time from this has allowed us to reduce quality down to an unrivalled four hours,” says Sören Witlake.quality down to an unrivalled four hours,” says Sören “Offline/online conversion software with a conversion assis- with a conversion conversion software “Offline/online tant on the machine makes format changes as simple as can be. In the KDF 6MF LEAD, the fully automated adjustment of

- - - - uilt on the experience and success and experience the on built the brand-new KDF 6MF LEAD from the on the brand-new KDF 6MF LEAD from auni unveiled the new multifilter maker at its in- house exhibition in November 2016. The feed back international audience was overwhelmingly posi- This came as no surprise: the development of the high- tive. maker multifilter quality KDF 5MF (launched in 2013) and tech of the high-precision renowned which is the KDF 6LEAD filter maker, nology from result is the most versatile “The for its outstanding flexibility. available on the market for the rap multifilter maker currently The KDF 6MF LEAD runs up to 600 m sector. idly growing end faster than the KDF 5MF and produces 20 percent Witlake, explains Sören of the highest quality,” products Consultant at Hauni. “The focus on flexibility perme Product ates the whole machine. Customers can extend the stand- configuration of our new flagship model with modules for ard H

was LEADer OF THE PACK in the high-speed range from 600 m/min. 600 from in the high-speed range THE KDF 6MF LEAD MULTIFILTER MAKER THE KDF 6MF LEAD MULTIFILTER presented for the first time at the end of last year. year. of last time at the end the first for presented

It stands for precision and unprecedented flexibility flexibility and unprecedented precision It stands for

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HiLiTE 1_17 HiLiTE CHALLENGES SOLUTIONS

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Hauni sets a new standard in efficient format conver- sion with its innovative, oil-free accelerating drum CONFIGURATIONS for flexible formats. GALORE

the transfer wheel optimizes the brand change at the sensitive introduced for the KDF 6MF LEAD with safe, dry and easy- With the option of retrofitting and combining additional transfer point from the drum to the rod maker. “As well as the to-handle conversion units in boxes (see article p. 12) un- modules for standard and special applications, the traditional design, we also offer the Flex Drum concept for derlines Hauni’s focus during the product development pro- KDF 6MF LEAD offers manufacturers maximum versa­ the KDF 6MF LEAD. This is suitable for use with all formats cess. This is confirmed by the optional EYEPORT one-for-all tility. The system is capable of making all the products and dramatically reduces conversion costs. The redesigned sensor system featuring a wide range of sensor modules. widely available on the market today. acceleration drum features innovative concepts for reducing Modules, such as the MIDAS-MD capsule detection system, the complexity of adjustment processes. These include the enable customers to perform additional quality control tests flexible format track, which can be adjusted without disman- tailored precisely to the specific filter they choose from the Basic module tling the drum and significantly cuts the conversion time. Oil- huge range of special filters available. The new 600 m/min. This additional standard module enables the KDF 6MF LEAD free lubrication guarantees product quality and also minimizes machine also offers an impressive range of logistics options. to produce triple and split-triple filters. The compact filter maintenance. “Overall, our LEAD concept offers advantages “The basic version of the maker offers a tray-based filter feed module has the minimum number of drums and is ide- not only in terms of radically faster conversion times,” ex- feed so manufacturers are not obliged to invest in additional 1 al for efficiently processing established base filter rods with plains Sören Witlake. “Optimized machine handling, made logistics. This is a unique selling point in the market,” explains materials such as mono-acetate, charcoal, crepe paper, non- possible by our LEAD developments, also pays significant Sören Witlake. “In addition, customers can use feed sys- wrapped acetate, channel ventilation, capsules and thread. dividends through time saved in cleaning, maintenance and tems such as RTS mass flow feed, a FILTROMAT-D or semi- repair work.” automatic tray unloading of base rods. For the paper supply, there is the option of using an internal bobbin changer or a Additional module Options for greater flexibility BOB-ME bobbin loader.” = This additional special module not only enables the The optional extras for the latest addition to the KDF family KDF 6MF LEAD to manufacture triple and split-triple filters, also show that Hauni is clearly focusing on workload reduc- but also to process materials that are difficult to cut and tion and flexibility for its customers. The smart brand change handle, e.g. NWA tube, PLA foil or cardboard tubes. The 2 flexible, modular drum configuration can be adapted to Familiar LEAD technology in a new specific production requirements. machine environment: no tools are needed to replace the new, flow- optimized suction shoe. Combination for quadruple filters Manufacturers who choose to extend their KDF 6MF LEAD configuration with an additional standard and a special module also gain the capability to produce quadruple filters with materials which are difficult to cut and push. 3 These materials include NWA tube, logo shape, cardboard

tubes and PLA foil. HiLiTE 1_17 HiLiTE

43 44 HiLiTE 1_17 CHALLENGES + SOLUTIONS “ N are notjustabletomanufacture everynon-wrappedshape filters toNWA fullfilters.Atthesametime,machines a broad spectrumofproducts –from thin-walledhollow past sixmonths.”Theprocesses are generallysuitable for manufacturing king-sizeanddemi-slimhollowfiltersforthe going fieldtestingatacustomer’s plantandhasbeen Manager atUniverselle.“Thisfilterlineiscurrently under And there ismore tocome,”reports MartinSinjen,Product speedof250m/min.usingthetampingprocess.duction “In ourextensivetests,wehavealready achievedapro rather thananozzle. the pullprocess (NWP)–therod isformedusingatape through adryingarea. Inthetampingprocess (NWT)–unlike between the triacetin and acetate. The rod then passes energy acceleratesthediffusion andbondingprocesses Here theenergyofsteampassesintorod. This tow istransportedthrough azonefilledwithhotsteam. – thepullandtampingprinciplesinasinglemachine.The Hauni presents aworldfirst: amachinewithtwoalternativeprocesses for the production of non-wrapped FILTER thinner walls.” to make even hollowfilters with The NWTprocess enablesus Martin Sinjen,Product ManageratUniverselle two different processes formakingthesefilters KDF 2ERistheonlymachinethatcombines in importancethecigarette industry. The o n-wrapped hollowfiltersare rapidlygrowing DIVERSITY HOLLOW FILTERS

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inspection ofendproducts inthemaker. camera-based ICPS-CSsensorfor100percent optical Hauni’s developersalsofoundawaytointegratethenew, With this inmind,larly importantinthearea ofspecialfilters. during thedevelopmentofNWA maker. Thisisparticu- from product diversity, qualitywasoneofthetoppriorities imaginable butalsotraditionalmono-acetatefilters.Apart .

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CROSS SECTION CHECK I with aflexible, modulardesign for Hauni haslauncheditsfirst development inanew modularcamera system –theICPS-CS maximum speed ofthemachine.” filter the cross section(CS)onlineandejectscigarette filtersor ICPS-CS hasahighresolution camerasystem explains ChristianLux,Product ConsultantatHauni. “The fies thatmaterialsare accurately shapedandlookperfect,” these newandcomplexspecialfilters,qualitycontrol veri “Withmanyfilters incigarette, of filterand multifiltermakers. of itstypetoprovide reliable opticalmonitoringofspecial developed anopticalsensorwhichisthefirstseriessolution pensive anddelicatefilters. To meetthisdemand,Haunihas r ods thatdonotmeettheexpected opticalqualityata control technologiestomonitor theserelatively ex facturers thushaveagrowing needforreliable quality portant tool for positioning tobacco products. Manu- n manymarkets,specialfiltersare anincreasingly im t hat inspects SPECIAL FILTERS - - -

the cross section.” controls whichanalyzethemfrom theoutsideandthrough can subjecttheirproducts tocomprehensive, reliable quality Optical Cigarette InspectionSystem(OCIS),manufacturers growing marketforspecial filters.“Incombinationwithour is theperfectcomplementarysystemforqualitycontrol inthe machine’s visualization. AsChristianLuxexplains,ICPS-CS and isexceptionallyuser-friendly duetoitsintegrationinthe tifying defectswhichprevious sensorswere unabletodetect only asoftware update.The systemisalsocapableofiden ing thesensortoanewspecialfilterorspecification requires lines thescopeandpowerofmodularapproach. Adapt- wide rangeofexistingandfuture specialfilters.Thisunder The manufacturer canusethesamehardware toinspecta to checkthefiltercross section.

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SOLUTIONS 45 HiLiTE 1_17 HiLiTE EXPERIENCE + RESPONSIBILITY HiLiTE 1_16 47

- ARC Advisory Group Florian Güldner, Director of Research, of Research, Director Florian Güldner, occur due to human errors.” occur due to human errors.” unscheduled plant shut-downs can can unscheduled plant shut-downs be attributed to a failure to observe to observe be attributed to a failure “It is estimated that 20 percent of all of all percent “It is estimated that 20 defined processes and that 40 percent and that 40 percent defined processes Major disasters are only the tip of the iceberg only the tip of the iceberg Major disasters are pro regarding key figures Along with turnover and profit, and gaining more and industrial safety are cess reliability take “When you industry. in the process significance more companies for arise that costs overall the consideration into and technical reliability in defects incidents, accidents, from it makes sense to focus on such topics,” operational safety, ARC Advi- at of Research Director explains Florian Güldner, for both the human factor and and responsible sory Group in this costs incurred Industry 4.0. “In many companies, the of turnover, percent of up to three a proportion way reach of the profit, percent which can mean as much as 15 to 20 Experience in the nuclear industry depending on the sector. the frequency shows that these costs and and aerospace reduced with suitable of major disasters can be significantly measures.” - - - - - t first glance, large-scale disasters such as the re as the such t first glance, large-scale disasters trag- actor accident in Fukushima, the Challenger Mile at the Three meltdown edy and partial core seem to Island nuclear power plant in Harrisburg A be harsh blows of fate for humankind – unavoidable conse be harsh blows of fate for humankind tak However, quences of natural events or material defects. the human factor always seems that ing a closer look reveals situations. Even decades in escalating to play a crucial role have changed nothing at to automate processes of efforts industrial the to significantly contribute still beings Human all: risk of large and small incidents. systems and complex processes the more On the contrary, fully of remaining become, the less the individual is capable situation and of always taking appropriate of the entire aware action. Many companies handle this situation like a rabbit at all and hoping for caught in the headlights: by not reacting lies primarily in the subconscious con the best. The problem deal can be done against unpredict viction that not a great in plant as the cause of human errors ability and unreliability operation. This attitude perpetuates incidents and accidents the fact that the most frequent in industry and disregards a lack of competence amongst causes of such events are employees or negligence in adhering to defined processes.

but even simple measures simple measures but even Accidents, explosions, falls – – falls explosions, Accidents, cant role in large-scale disasters. in large-scale cant role human errors usually play a signifi- usually play errors human

A SUBSTANTIAL PROCESS RISK, A SUBSTANTIAL

Human errors pose Human errors applications. in industrial safety and availability increase considerably A REMAINING RISK: A REMAINING RISK: THE HUMAN FACTOR

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HiLiTE 1_17 HiLiTE 48 HiLiTE 1_17 EXPERIENCECHALLENGES + RESPONSIBILITY + SOLUTIONS technology, routines, plantoperationandhuman behaviour.” is onlyachievedhere bycombining integratedapproaches, a cost-effective manner,” saysGüldner. “However, success a corresponding safetyculture canclearlyreduce theriskin substantially underestimated. Maintenance, technology and average financialeffects of seriousindustrialincidentsare financial performance,andvariousstudiesshowthat the process reliability haveadecisiveimpactonanycompany’s the company’s reputation. “Ingeneral,plantavailabilityand ronment ortheequipment, involvinghighcosts and ruining may leadtopersonalinjuryorevendeath,harmtheenvi At worst,“incidents”,accidentsandunwantedshut-downs a direct positiveeffect ontheresults ofindustrialcompanies. address thisissue,assafetyandplantavailabilitybothhave a planecrashorcore meltdownare alsorecommended to Even companiesthatdonothavethepotentialofproducing to make therightdecisionsinstressful “Trained employees are more likely a 1:1simulatedplantandvirtual situations. Realistic training with Florian Güldner, Director ofResearch, reality isimportanthere.” ARC AdvisoryGroup

- appropriate measures.” risks are considerablyreduced bymeansoffasterand more mation,” saytheauthorsintheirwhitepaper. “Theoperative decisions canbemadeonthebasisofcurrent systeminfor creasingly complexindustrialplants.“Inurgentcases,viable major leverinimproving thereliability andavailabilityofin- development and operation of a plant, the analysts see a database andwhichisavailabletoallthoseinvolvedinthe intoan“as-maintained” built” databaseandgraduallyturns a consistentandglobaldatahub,whichstartsoff asan“as- with constantdatacollectionlongbefore accidentsoccur. In structure, come to the conclusion that asafety culture begins research andconsultationcompanyforindustryinfra Güldner from theARCAdvisoryGroup, aleadingtechnology Safety Risks”,theauthorsValentijn deLeeuwandFlorian Practices Improve ReliabilityandReduceOperational In theirwhitepaper“GoodAssetInformationManagement Information creates reliability analysis, development efficiency checkand data collectionand increased safety: documentation. Five stepsfor of measures,

- - him ofhiscreativity. Thisiswhere theaspectofartificial capacitates the human being in the factory, thus depriving at leastmakesapreliminary decision,whichpracticallyin- decisions made.“More andmore frequently, thecomputer plant, onthebasisofwhichsimulationscanbecreated and rect andcurrent digitalimageandhenceatwinof ronments theaimistocreate asystembymeansofcor major role inthiscontext.Inbothcases,industrialenvi ofThings” and“BigData”playa The keyterms“Internet Digital twinsandartificialintelligence the limitsoftheirsensory, motor, cognitive andattention-related People make mistakes when capacities are exceeded.

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operational readiness and improves adherence tostatutory reduces operativerisk,boosts productivity, ensures faster handovers, operation and maintenance to beuseful. This dated datahubfordesign,engineering,construction, Güldner considerstheuseofasingleconsistentandup- ways be up-to-date and available to all those involved, digital twins,amongstothers.Asatwinmustal tions canbecreated giventherighttools.”Theseinclude lem isfilteringtheinformation.Perfectframeworkcondi This creates theillusionofcontrol, buttheactual prob an operatorcanprocess. ready havemore dataandinformationatourdisposal than by theinteractionofhumanandartificialintelligence. We al bear inmindthatfuture, thebestdecisionswillbemade intelligence comesin,”explainsGüldner. “Here weneedto regulations inconjunction with 3Dplantvisualization.

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50 HiLiTE 2_161_17 Professor JuliaYeomans, Oxford University creating tinyengines.” Nature isbrilliantat EXPERIENCE + + RESPONSIBILITY RESPONSIBILITY WINDFARM BACTERIAL http://advances.sciencemag.org/content/2/7/e1501854.full derstand howtoexploitsimilardesigns,”sheconcludes. tiny engines,andthere isenormouspotentialifwecanun the potentialofthisresearch. “Nature isbrilliantatcreating Julia Yeomans, thestudy’s seniorauthor, ishopefulabout the needforanadditionalelectricalpowersupply. Professor be usedtopowermicroscopic machinesbiologicallywithout The teambelievethatthisconstantstream ofenergycould rotors were usedindividually. Department ofPhysics.There wasnoeffect whenthe farm,” explainsDrTyler Shendrukfrom Oxford University‘s The rotors justself-assembledintoasortofbacterialwind- to pre-design microscopic gear-shapedhave turbines. opposite direction. “The amazingthingisthatwedidn’t and generatedacurrent therotors whichturned inthe result wasastonishing. The bacteriaorganizedthemselves 64 symmetricallyarrangedmicrorotors inthesolution, manner. However, whentheOxford teamplaced agridof swimming around afluid-filled petridishinarandom Left totheirowndevicesbacteriabehaveerratically– microscopic scale. shown thatthisprinciplealsoworksonthe new experiment atOxford University has jures upimagesof awindfarm. Buta ing to generate power immediatelycon- BACTERIA: The ideaof rotor bladesturn-

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51 51 RESPONSIBILITY EXPIERIENCE HiLiTE 2_16 1_17 HiLiTE HiLiTE

52 HiLiTE 2_16 EXPERIENCE + RESPONSIBILITY

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53 RESPONSIBILITY HiLiTE 2_16 HiLiTE EXPERIENCE + RESPONSIBILITY RESPONSIBILITY NETWORKING EXPERIENCE + FROM DAY ONE

In their final practical projects,HAUNI’S TRAINEES regularly demon- strate that their abilities are well above average in the sector.

auni has consistently offered high- adequate to purchase quality apprenticeships to young finished parts. From people for decades. It is a key providing materials to element of the company’s sustain- delivering the product, Hability strategy. So perhaps it is not surprising the four mechatronics that Hauni’s four mechatronics trainees appear apprentices made many relaxed as they look forward to their Chamber of of the components for their Commerce examinations. “After the final projects miniature factory themselves. they presented to us here, these tests should When necessary, they turned to pose no problem,” explains Gerald Glaeser, a Hauni experts for advice on practi- mechatronics instructor at Hauni. “In just ten cal and conceptual matters. “The sup- weeks, Nadja Schulte, Yana Xu, Ole Schmidt and port was amazing and we all benefited Even Niemeyer planned, built and programed a from having worked in various departments modular production system that can be operated during our training. It meant we already knew using a control panel. We presented it at our in- a lot of people we could contact,” says Ole house exhibition in November.” Schmidt, highlighting the friendly atmosphere Glaeser believes the high standards expected within the company. “Many of the experts here from the apprentices are entirely justified. After remembered what it was like to be in our po- completing the program, trainees have to be sition and were happy to offer us advice and ready to take up positions with Hauni and main- practical assistance.” tain the outstanding level of quality for which the For their instructor Gerald Glaeser, this coop- company is renowned. During the project, these erative spirit is a major advantage of appren-

four young people have demonstrated their ticeships at Hauni: “Ultimately, Hauni’s expertise Hauni mechatronics abilities beyond doubt. “In planning and building depends on developing specialist knowledge apprentices Even our mini-factory, we had to use all the knowl- and effectively exchanging it with others. The Niemeyer, Nadja edge and skills we acquired during our appren- professionals in our departments work together Schulte, Yana Xu and ticeships – from mechanics, electrical systems as a single large network. Everyone who has Ole Schmidt present the and control technology to assembly, design, completed an apprenticeship with us already results of their chal­ project planning and time management,” says knows colleagues in a number of our depart- lenging final project: Nadja Schulte. “We not only had a fixed budget, ments. They can contact each other whenever a modular production which Hauni has provided for this purpose for necessary in order to achieve the best possible system that can be oper­ the last 15 years, but were also able to look for results for our customers.” = ated via a control panel. support within the company.” This was impor- tant because the budget is not intended to be Watch videos with the new HiLiTE App

HiLiTE 1_17 for browsers and mobile devices.

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VR PREVIEW HiLiTE 1_17 55 P. 46-47: fotolia/dbunn (l.), F1online/Sigrid P. (Icons) shutterstock/graphix- Gombert (r.), (r.), mania (l.)/VoodooDot Fischinger (l.)/ 48-49: F1online/Mareen P. (c.), (Icons) fotolia/Dron John Feingersh (r.), Shutterstock/graphicmania (3), 50-51: American Association for P. fotolia/ Advancement of Science (t.l, b.r.), b.l.), Jezper/psdesign (t.r., 52-53: Sebastian Vollmert, P. 54: Getty images/Ascent Xmedia, P. 55: Hauni (t.,c.), Courtesy NASA/ P. JPL-Caltech (b.) Printed by: Beisner Druck GmbH & Co. KG, Buchholz near Hamburg © May 2017 Hauni Maschinenbau GmbH Microsoft Deutschland GmbH/ 28-29: Microsoft P. (l.), Hauni (r.), Patrick Schuchardt 30-31: (Collage) F1online/Philippe P. TURPIN, PR, 32-33: Hauni, P. 34-35: (Collage) Dreamstime.com/ P. F1online/Robert Seitz (l.), Muro123, Hauni (r.), (t.), Hauni (b.), 36: Dreamstime.com/Utorro P. 37: mauritius images/Johnér (l.), Hauni (r.), P. 38-39: pixelwg/Jörg Häckel (l.), Hauni/ P. Christian Geisler, 40-45: Hauni, P.

Articles authored by: Articles authored Christiane Müller, Mirjam Müller, Dirk Schulte Translations: AG Cerebro Westerdale, Edward Lithography: Dunz-Wolff Mediendienstleistungen GmbH, Hamburg + VISIONS + RESPONSIBILITY + SOLUTIONS

(Collage) fotolia/olly, 8-9: (Collage) fotolia/olly, P. (r.), iStock/chinaface (l.), rosendo 10: (Collage) fotolia/alexey_m, iStock/ P. Dkart, 11: (Collage) iStock/julianvalentin/Liufuyu, P. (r.), 12-13: Hauni (l.), Sebastian Vollmert P. 14-15: Sebastian Vollmert, P. 16-17: pixelwg/Jörg Häckel, Hauni, P. Christian Geisler (l.), Hauni, P.18-19: 20-25: fotogloria/Philippe Roy, P. 26: Getty Images/Justin Sullivan/Staf, P. (t.), 27: iStock/Wavebreakmedia P. mauritiusimages/Roman Märzinger (b.), Publishing agency: claim GmbH, Hamburg Publishing Manager & Art Buying Birgit Dörfer Phone: +49 (0)40 4327 5311 www.claim.de Editor-in-chief: Mirjam Müller Hamburg www.mirjam-mueller.de, Art direction: claim GmbH Matthias Welker,

CHALLENGES RECLAIMING TOBACCO reclaiming system first tobacco Hauni developed the is now over 20 years ago. Its subsidiary Decouflé i-Loop – the next generation of to present proud Suitable for all makers solutions. tobacco reclaiming flexibility speed of 20k and with the up to a production layout requirements. for individual required COMPETENCE TRENDS 2018 TOBACCO tobacco sector the to traditional cigarettes, In addition edi- markets. The next many exciting niche is home to in insights into the latest trends tion of HiLiTE will offer as the cigars, tube and shisha, as well snus and snuff, Hauni. solutions from product corresponding EXPERIENCE GREEN WALL GREAT an 8,000 kmIn 2007, the African Union began planting the continent. It is a new strategy across wall of trees in the Sahel in the fight against hunger and drought the coast to coast across from zone, which stretches continent to the south of the Sahara.

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Hauni Maschinenbau GmbH for content: Gitte Möller Jörg Walter, Hauni Maschinenbau GmbH 8 - 32 Kurt-A.-Körber-Chaussee D-21033 Hamburg Phone: +49 (0)40 7250 2992 Fax: +49 (0)40 7250 3720 [email protected] www.hauni.com Cover: (Collage) Panther Media, shutter- stock/Zastavkin/Aila Images/Leolintang/ Kamenetskiy Konstantin; fotolia/Elnur; 123RF/cheskyw, 2: (Collage) F1online/Justin Case, P. fotolia/AlenKadr, 3: Sebastian Vollmert, P. 4: fotogloria/Philippe Roy (l.), Cover P. image (r.), 5: Getty Images/Justin Sullivan/Staf (t.l.), P. Hauni (b.l.), mauritius images/Johnér (t.r.), (Collage) F1online/Philippe TURPIN, PR (b.r.), 6-7: fotogloria/Philippe Roy, P. Publisher: Responsible

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HiLiTE App – Watch videos with the new Watch for browsers and mobile devices. VR an average speed of 130 km/h. The record for the longest an average speed of 130 km/h. The record held by the American Dean wingsuit BASE jump is currently the summit of the Eiger in Switzerland leapt from who Potter, minutes two km over the next a distance of 6.5 covered He and 50 seconds. it to open parachute, land: cord Jump, glide, pull release all too but serious accidents are sounds simple in theory, as these experienced birdmen, in practice. Even common sports enthusiasts call themselves, make mistakes, extreme such as misjudging thermal conditions or their height above the ground. The consequences are often fatal. often fatal. The consequences are the ground. - ly like a bird. According to the Greek myth, the first the myth, Greek the to According bird. a like ly reality ended attempt to turn of flight into a the dream with a dramatic crash. The inventor Daedalus made

wings for himself and his son Icarus to escape from their from escape to Icarus son his and himself for wings his Icarus ignored Tragically, prison on the island of Crete. warning the sun. His overcon to too close fly to not father’s Icarus wings melted and fatal: the wax in his proved fidence plummeted to his death. countless ways to defy Since then, mankind has discovered But the history of human flight is still being written, gravity. In this spectacular and wingsuit flying is the latest chapter. special nylon – a a “wingsuit” wears parachutist the sport, by the anatomy of flying squirrels. Wingsuit flyers suit inspired mountain tops and skyscrapers, reaching aircraft, leap from EXTREME SPORT EXTREME SPORT WINGSUIT FLYING F

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HiLiTE 1_17 HiLiTE FUTURE – MADE BY HAUNI